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Related Manuals for UTICA BOILERS UB90-200
Summary of Contents for UTICA BOILERS UB90-200
- Page 1 UB90 125-200 GAS-FIRED, DIRECT VENT, CONDENSING, HOT WATER BOILER INSTALLATION, OPERATION & MAINTENANCE MANUAL Utica Boilers 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com An ISO 9001-2008 Certified Company P/N 240004826U, Rev. B [08/11]...
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Page 2: Table Of Contents
90 125-200 CAST ALUMINUM BOILER Safety Symbols ........................... 2 Rules For Safe Installation And Operation ..................3 Boiler Ratings & Capacities ......................4 Before Installing The Boiler ......................5 Placing The Boiler ........................9 Near Boiler Piping ........................10 Combustion Air And Vent Pipe ......................13 Gas Supply Piping ........................15 Electrical Wiring .........................16 Controls And Accessories ......................20... -
Page 3: 90 125-200 Cast Aluminum Boiler
90 125-200 CAST ALUMINUM BOILER This appliance, unlike normal residential atmospheric and Introduction induced draft units, takes its combustion air directly from This appliance is a gas-fi red direct vent cast aluminum the outdoors (sealed combustion) and does not compete hot water boiler. -
Page 4: Boiler Ratings & Capacities
BOILER RATINGS & CAPACITIES Figure 1 -Boiler Jackets TABLE #1 - SEA LEVEL RATINGS (NATURAL AND PROPANE GASES) Input Heating Capacity Net I=B=R Rating Shipping AFUE Model Flue Diameter (1)(2) (MBH) (MBH) (MBH) Weight (lbs.) 90.0 2” CPVC & 3” PVC 90.0 2”... -
Page 5: Before Installing The Boiler
BOILER RATINGS & CAPACITIES TABLE #3 - LP GAS 200,000 175,000 150,000 125,000 Nominal Input Vent Lengths Vent Lengths Vent Lengths Vent Lengths Altitude Min. Min. Min. Min. 200,000 200,000 175,000 175,000 150,000 150,000 125,000 125,000 1,000 195,900 195,750 171,900 171,200 146,900 146,700... - Page 6 BEFORE INSTALLING THE BOILER In the State of Massachusetts: Locating The Boiler Select location which is level, central to piping systems • This product must be installed by a licensed plumber served and as close to vent and air intake terminals as or gas fi...
- Page 7 BEFORE INSTALLING THE BOILER Advise owner of boiler to keep venting and combustion air intake passages free of obstructions. Both venting Figure 2 - Sidewall Vent/Intake Terminations and combustion air intake piping systems connected to outdoors must permit fl ow through piping systems OVERHANG without restrictions for boiler to operate.
- Page 8 BEFORE INSTALLING THE BOILER Combustion Air/Vent Pipe Requirements Continued Figure 5 - Concentric Vent Roof Installation WARNING Failure to follow these warnings could result NOTE: VENT in fi re, property damage, personal injury, or SUPPORT MUST BE death. FIELD INSTALLED TO SECURE TERMINATION When vent pipe is exposed to temperatures KIT TO STRUCTURE.
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Page 9: Placing The Boiler
BEFORE INSTALLING THE BOILER Foundation Requirements In so far as is practical, close all building doors and windows and all doors between the space in which the Boiler must be placed on level surface. Boiler is NOT to be appliances remaining connected to the common venting installed on carpeting. -
Page 10: Near Boiler Piping
NEAR BOILER PIPING Expansion Tank And Make-Up Water CAUTION Determine required system fi ll pressure, system design Copper supply and return piping must not be temperature, and system water content. Boiler contains 2.6 gallons (U.S.). Size expansion tank accordingly. Consult installed directly into aluminum boiler section expansion tank manufacturer for proper sizing information. - Page 11 NEAR BOILER PIPING • Individual boiler discharge piping shall be Figure 9A - Multi-zone Boiler Piping with Circulators independent of other discharge piping. • Size and arrange discharge piping to avoid reducing safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate.
- Page 12 NEAR BOILER PIPING Condensate Drain Requirements Condensate Drain Piping Condensate drain line to be pitched down to fl oor Condensate trap is to be fi eld installed as previously drain at minimum of ¼” per foot (21mm/m). External shown in Figure #10. Provided are ½” PVC fi ttings for condensate pump (not furnished) may be used if condensate drain trap (assembled in fi...
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Page 13: Combustion Air And Vent Pipe
COMBUSTION AIR AND VENT PIPE Length of pipe is counted from boiler jacket (air intake Connections And Termination pipe) or from vent tee (vent pipe). First fi ve feet of “Total NOTICE Equivalent Length” of vent pipe must be CPVC. Reduce maximum vent length 5 feet per each additional To prevent damage to gas burner and ensure elbow. - Page 14 COMBUSTION AIR AND VENT PIPE Consideration for following should be used when Canada - Terminate vent system at least 6 feet (1.83m) determining appropriate location for termination of horizontally from, and in no case above or below, combustion air and vent piping: unless 6 feet (1.83m) horizontal distance is maintained, •...
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Page 15: Gas Supply Piping
GAS SUPPLY PIPING Use ground joint unions. Check Gas Supply Install sediment trap upstream of gas controls. TABLE #5 - GAS SUPPLY PRESSURE Use two pipe wrenches when making connection to Pressure Natural Gas Propane Gas gas valve to keep it from turning. Minimum 4”... -
Page 16: Electrical Wiring
ELECTRICAL WIRING Figure 13 - Field Wiring Connection WARNING Turn off electrical power at fuse box before making any line voltage connections. Follow local electrical codes. All electrical work must conform to local codes as well as National Electrical Code, ANSI/NFPA-70, latest revision. In Canada, electrical wiring shall comply with Canadian Electrical Codes, CSA-C22.1 and .2. - Page 17 ELECTRICAL WIRING Run 14 gauge or heavier copper wire from boiler to Set heat anticipator at 0.7 amps. Connect 24 volt thermostat grounded connection in service panel or properly driven leads to the two (2) yellow wires located in service switch and electrically grounded ground rod.
- Page 18 ELECTRICAL WIRING Figure 14A - Schematic Wiring Connections NOTE: If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 150°C Thermoplastic wire or its equivalent. 1013-10 INTEGRATED BOILER CONTROL CASTING TEMPERATURE SAFETY SWITCH (MANUAL RESET) HI LIMIT 24 VAC AQUASTAT...
- Page 19 ELECTRICAL WIRING Figure 14B -Ladder Wiring Diagram NOTE: If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 150°C Thermoplastic wire or its equivalent. 120 VOLT POWER SUPPLY (NOTE: USE COPPER CONDUCTORS ONLY) ON/OFF SWITCH LWCO...
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Page 20: Controls And Accessories
CONTROLS AND ACCESSORIES This section provides a brief description of the key controls Figure 16 - Indicator Lights and accessories found in this boiler. See, “Troubleshooting,” page 33 in this installation manual for detailed sequences of operation and troubleshooting procedures. See the separately provided “Repair Parts Manual”... - Page 21 CONTROLS AND ACCESSORIES Differential Pressure Switches Failure to provide the pressure relief valve with piping as The diaphragm type differential pressure switches are herein described may cause water damage and/or serious connected by vinyl tubing to the gas valve and the air bodily injury.
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Page 22: Startup
STARTUP Water Treatment And Freeze Protection Antifreeze must be maintained per specifi cations of Consult local water treatment specialist for manufacturer. Failure to do so will result in warranty being recommendations if your water pH levels are below of voided. Follow antifreeze manufacturer’s instructions on 7.0 or hardness is above 7 grains hardness. - Page 23 STARTUP Open the zone service valve on the supply pipe for the Use only your hand to turn the gas shut off valve. fi rst zone. Open the purge valve on the fi rst zone. Feed Never use tools. If the valve will not turn by hand, do water will fi...
- Page 24 STARTUP NOTICE If burner appears to pulsate during ignition: Turn off boiler power and shut off gas supply to the boiler. Take the burner assembly apart by removing the combustion air blower and gas valve/ venturi assembly from the boiler and visually inspect the inside of the burner. Look for any debris (pvc shavings, etc.) And if anything is present, remove it.
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Page 25: Checkout Procedure & Adjustments
CHECKOUT PROCEDURE & ADJUSTMENTS Verify Proper Sequence Of Operation The sequence can be followed via the diagnostic indicator lamps on the Integrated Boiler Control in Figure #16 ( Section: Controls and Accessories). This is the normal sequence of operation. A more detailed sequence of operation containing potential faults can be found in the service hints section. - Page 26 CHECKOUT PROCEDURE & ADJUSTMENTS Inspect Venting & Air Intake System Set Thermostat Heat Anticipator (If Used) And Verify Thermostat Operation Operate the boiler and verify that all vent/air intake connections are gas-tight and water-tight. Repair any leaks For a single thermostat connected to the yellow thermostat immediately.
- Page 27 CHECKOUT PROCEDURE & ADJUSTMENTS NOTICE Adjustments and checkout It is important that this appliance operate between 8.5 And 10% co2. To verify that the appliance is operating in this range, follow the steps below. Important: under all conditions co levels should not exceed 100ppm. Check incoming gas pressure to the appliance using a pressure gauge with a resolution of 0.1”...
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Page 28: Maintenance And Cleaning
MAINTENANCE AND CLEANING Check that boiler area is free from combustible NOTICE materials, gasoline, and other fl ammable vapors and Maintenance as outlined below can be liquids. performed by the owner unless otherwise Circulator pump and blower motor furnished with noted. - Page 29 MAINTENANCE AND CLEANING Annual Shut Down Procedure (End Of Each Heating Aluminum oxide deposits are water soluble and Season) may be rinsed away with spraying or running water. Follow the instructions in “To Turn Off Gas To Appliance” page 23 of this manual. Use a fl...
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Page 30: Detailed Sequence Of Operation
DETAILED SEQUENCE OF OPERATION SERVICE HINTS... - Page 31 DETAILED SEQUENCE OF OPERATION DRAFT INDUCER TEMPERATURE SAFETY SWITCH CASTING TEMPERATURE SAFETY SWITCH if draft inducer temperature reaches temperature safety switch If burner operates when boiler has no water, aluminum boiler set-point, safety switch contacts open immediately, closing gas sections heat up rapidly. (light goes out) valve Casting temperature safety switch contacts will open, breaking...
- Page 32 DETAILED SEQUENCE OF OPERATION End Of Normal Sequence Of Operation Thermostat ends call for heat. Gas valve and circulator pump are de-energized, valve and fl ame lights go out. Blower runs for 30 seconds post purge, purge light is on. Blower is de-energized after 30 seconds, purge light shuts off.
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Page 33: Troubleshooting
TROUBLESHOOTING IMPORTANT DANGER Initial Service Checks Fire, explosion or shock hazard may cause Before Troubleshooting: severe injury or death. Do not attempt to Make sure that the circuit breaker is on or fuse is modify the physical or electrical characteristics OK at the electrical panel. - Page 34 TROUBLESHOOTING System Status The indicator lights track the operating sequence. If the system locks out, the lights indicate the point in the sequence of operation were lockout occurs. If this table does not readily provide the reason for boiler malfunction or non-operation, refer to the following pages for more detailed troubleshooting procedures.
- Page 35 TROUBLESHOOTING Troubleshooting Chart 1 WARNING Electrical shock hazard May cause serious injury or death The following procedures may expose you to dangerous line voltage. Use caution to avoid touching live electrical contacts. Service must be performed by a trained, experienced service technician.
- Page 36 TROUBLESHOOTING Troubleshooting Chart 2...
- Page 37 TROUBLESHOOTING Troubleshooting Chart 3 CHART 1 OPEN CHECK FOR VAC BLOWER STARTS BETWEEN TERMINALS 1 AND 3 REPLACE IBC AT CONNECTOR CN4 ON IBC CHECK FOR 120 VAC AT REPAIR/REPLCE BLOWER LEADS ON WIRING WIRING FROM IBC HARNESS TO BLOWER REPAIR/REPLACE BLOWER PRESSURE SWITCH...
- Page 38 TROUBLESHOOTING Troubleshooting Chart 4 CHART 3 CHECK FOR 120 VAC IGNITER/SENSOR WARMS BETWEEN TERMINALS 1 UP AND GLOWS AND 2 AT CONNECTOR YELLOW/ORANGE REPLACE IBC CN1 ON IBC (DURING DURING 20 SECOND IGNITER WARM UP) WARM UP CHECK FOR 120 VAC AT IGNITER/SENSOR LEADS REPAIR/REPLACE WIRING ON WIRING HARNESS...
- Page 39 TROUBLESHOOTING Troubleshooting Chart 5...
- Page 40 TROUBLESHOOTING Troubleshooting Chart 6 CHART 5 CHART 5 CHART 5 REPLACE GAS CONTROL. NO #3 NO #2 CHECK GAS ORFICICE SIZE. IS GAS ORIFICE SIZE CORRECT. CHECK REPAIR PARTS LIST FOR CORRECT SIZE. IS GAS ORIFICE CLEAR OF BLOCKAGE. RUNS FOR 25-50 SECONDS, THEN TURNS OFF.
- Page 41 TROUBLESHOOTING Differential Air Pressure Switch Check Locations Of The Connection Points Required To Check The Diff erential Air Pressure. The differential air pressure switch is safety device which will prevent boiler from fi ring if there is air intake, boiler heat exchanger or vent blockage.
- Page 42 This Page Intentionally Left Blank...
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Page 43: Installation And Check-Out Certifi Cate
INSTALLATION AND CHECK-OUT CERTIFICATE Boiler Model ___________ Serial # _____________ Date Installed___________ Measured BTU/HR input ____________ Installation instructions have been followed Checkout procedure and adjustments performed Maintenance and Service issues reviewed with owner/ maintenance person Installation booklet affi xed on or adjacent to boiler Installer (Company) __________________________________________ Address ___________________________________________________ Phone _____________________________________________________... - Page 44 UTICA BOILERS 2201 Dwyer Avenue Utica NY 13501 web site: www.ecrinternational.com...